Century Rayon

CENTURY RAYON Environmental and Occupational Health & Safety Policy Century Rayon is the leading manufacturer of Viscose Filament Yarn and Chemicals. The company is committed to the protection of the environment and the health and safety of its employees, customers and community. In this vein the company shall: Regularly review objectives for attaining continual improvement in environmental and occupational health and safety performance. Be committed to prevention of pollution. Implement continual improvement in resource conservation i.e.: Raw Materials and utilities like Energy and Water. Take measures and ensure safe work environment towards reduction of accidents. Monitor and control work place hazards. Train and involve company's employees and contractor's workmen in Environmental and Occupational health and Safety performance. Ensure compliance of legal and other requirements and strive for further improvement. Century Rayon is committed for a cleaner and healthier environment. The Environmental and Safety Policy shall be communicated to all persons working for or on behalf of the organization and is available to the public on request. Date: 28.2.2007

President

CENTURY RAYON Environmental & Occupational Health & Safety Management System

Overview

ISO-14000 is a series of international, voluntary environmental management standards for better environment management. OHSAS-18000 is a set of authorities through which an organization maintains awareness & control over its interactions with worker health & safety. Interfaces directly with business objectives

CENTURY RAYON Definations Environmental Aspect: Element of organizational activities or products or services that can interact with the environment. Environmental Impact: Any change to the environment whether adverse or beneficial wholly or partially resulting from an organization’s environmental aspects. Hazard: Source or situation with a potential for harm. Risk: Combination of the likelihood & consequences of a specified hazardous event. SSPD Score: Product of individual weightages of scale, severity, probability & duration. EMP: Environmental & Occupational Health & Safety management program includes objectives, targets & action plan. EPR: Emergency preparedness & response for potential emergency situation & accident. M&M: Monitoring & measurement of key characteristics that can have significant impact / harm.

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

1

Process flow sheet – aspects to be linked to process flowA. / H. included activity.

no.

2

Cross Reference for aspects / significant aspects &Implemented objects/ targets / programs

3

Aspect of contributing factor to be rated

4

Procedure for issue, distribution & maintenance of PPE Implemented

5

External origin documents to be identified & records toImplemented be maintained.

6

Objectives to be displayed and communicated throughImplemented training.

7

Incident report, Frequency Report, Severity Report,Implemented Trend charts of near misses , incidents & accidents

Implemented

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

8

Toe Guard for stair cases.

Implemented

9

OCP to be modified as per clause 4.4.6.

Implemented

10

Environmental program - procedure to be modified forImplemented review, changes, benefits & closure of EMP

11

ETP - control measures to be provided for fall hazards. Implemented Plan for DO probe in aeration tank. Aspect & impact evaluation of foam suppression

12

Basic risk, residual risk with existing control, riskNew format classification & corresponding control plan to be includedfor Evaluation in the procedure.

13

M & M plan with frequency & for Key EnvironmentalImplemented performance Indicators (Water, power & Air etc.)

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

14

Companywide power consumption.

1% Reduction taken as an objective.

15

Trend of Environmental performance improvement.

Implemented

16

Procedure for legal requirement to include updating,Implemented responsibility for liaison with statutory bodies, M & M etc.

17

Evaluation of compliance- Legal / Statutory regulatoryImplemented requirement. (PCB Act, Bio medical waste, MV Act, Battery Rules etc.)

18

M & M (Legal) to be maintained at one definedImplemented department.

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

19

M & M for maximum permissible discharge limit ofImplemented sewage - evidence to be provided.

20

Management programs for sewage treatment withNot Required defined action plan.

21

Recycling of treated water & discharge of excess quantityImplemented through Waldhuni nallah - evidence to be provided.

22

The quality & quantity of treated effluent discharged toImplemented ulhas river thru waldhuni nallah - evidence to be provided.

23

The quality & quantity of effluent from each plant to ETPUnder to be measured and monitored - plan to be definedProgress against set norms.

CENTURY RAYON

Sr. No.

Pre-audit Observations of M/s TUV Particulars

Remarks

24

Water consent order Form No. 5 - consumption forImplemented Industrial cooling - evidence to be provided.

25

License for sulphur storage - evidence to be provided.

26

Monthly Form 3 of PCB to be filled for inventory / stocksNot Required of hazardous waste.

27

Non-ferrous metal waste - to be included in form 13.

28

Investigation format for incident/ accident to include 4.5.2Implemented clause of OHSAS 18001.

29

Water Budget, Water balance as per permitted quantitiesImplemented by MPCB - evidence to be provided.

30

Chlorine leaks , CS2 leaks , fire due to inflammableImplemented material to be included in onsite emergency plan.

Available

Implemented

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

31

Management programs for storage of waste oil.

Under progress

32

Hazards during cement unloading.

Implemented

33

Identification of hazardous waste chemical containers.

Implemented

34

Compressed gas cylinder - legal requirement for capping,Being taken as color coding & safety distance, test date and due dates toEMP be displayed on cylinders.

35

Housekeeping in scrap yards.

36

Procedure for maintenance including plant - dustImplemented collectors, scrubbers, blowers, ETP equipment - records to be maintained. Test records from external agency for chain pulley blocks & EOT Cranes.

Implemented

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

37

Training - Contractors, material movers, sub-contractorsUnder & transporters - for outside & inside people. Progress

38

Training Calendar to be made

39

Policy & Compliance with legal requirements to beUnder displayed outside. progress

40

Receiving, documenting and responding toImplemented communication from public to be updated & recorded

41

ISI marking on First aid & Fire fighting equipments

42

Canteen – Aspects & Hazards due to LPG leaks, fire dueImplemented to diesel storage, OCP for pest control, license for LPG cylinder storage

Implemented

Implemented

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

43

Dust collectors - OCP for downtime analysis, PMImplemented schedules, spare parts & efficiency measurements

44

List of E & S critical equipments – down time analysis ofImplemented ETP, dust monitors,& efficiency measurements – records to be maintained.

45

Drawing/Plot plan indicating domestic sewage lines,Implemented process waste lines, storm water drains, septic tank locations, ETP location, ambient air monitoring station, noise monitoring stations, hazardous storages, evacuation routes, entry, exits & assembly points. Sign boards at emergency exits to be provided

46

Management Review – Agenda to be reviewed to includeImplemented clauses

CENTURY RAYON

Pre-audit Observations of M/s TUV Sr. No.

Particulars

Remarks

47

Documentation System , Levels of Documentation,Implemented Review, Approval & Issue matrix.

48

Master List of Documents & records.

49

Drinking water analysis – Chemical & Bacteriological –Implemented As per ISI Standards.

50

Laboratory – Hazardous chemicals to be considered forImplemented Aspects / Impacts.

51

Overall Roles & Responsibility – As per the Clause

Implemented

Implemented

CENTURY RAYON DETAILS OF NON-CONFORMITIES – CLOSED (ROUND NO. 1) 1. Rayon Viscose (Production) In GCF section no SSPD analysis carried out and aspects /hazards are made significant without analysis. 2. Century Chemicals Laboratory Temperature is abnormal in chemical laboratory. It is unhygienic for staff and workmen especially during summer.

CENTURY RAYON Tyre Cord Plant 1.035

1.036 1.034 1.032

1.031

1.030 1.028

1.028

1.026

1.028 1.025

1.026

1.026 1.026

1.0251.023

1.024

1.026

1.026 1.026

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

Aug.'06

July '06

June '06

May '06

Apr '06

1.022 Apr'05- Mar'06

PULP (Kg./ Kg. Yarn)

Pulp Ratio – Apr ’05 to Mar.’07

CENTURY RAYON 3.67

3.77

3.62 3.58

3.39

3.4

3.43

3.27

3.2

3.31 3.12 2.92

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

Aug.'06

July '06

June '06

May '06

2.8

Apr '06

3.800 3.700 3.600 3.500 3.400 3.300 3.200 3.100 3.000 2.900 2.800 2.700

Power Ratio – Apr ’05 to Mar.’07

Apr'05- Mar'06

POWER (KWH /Kg. Yarn)

Tyre Cord Plant

CENTURY RAYON Tyre Cord Plant Caustic Ratio – Apr ’05 to Mar.’07 0.760

0 .7 5 5 0.747

0.70.746 48

0 .7 4 5 0 .7 3 5

0.73 0

0 .7 1 5

0.7140 .720

0.717

Ye a r

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

Aug.'06

July '06

June '06

May '06

Apr '06

0 .7 0 5

0.7 11

0.706

Mar.'07

0.717

Feb.'07

0 .7 2 5

0.7 30

0.725

Apr'05- Mar'06

CAUSTIC (Kg./ Kg. Yarn)

0 .7 6 5

Year

28

Mar.'07

37

Feb.'07

37

Jan.'07

Dec. '06

39

Nov. '06

36

Oct.'06

38

Sept. '06

Aug.'06

33

July '06

June '06

32

May '06

30

Apr '06

40 38 36 34 32 30 28 26 24 Apr'05- Mar'06

WATER (Gallons)

CENTURY RAYON Tyre Cord Plant

Water Consumption – Apr ’05 to Mar.’07 39

38

32 28

CENTURY RAYON 22.31 21.51

21.53 21.47 20.73

21.07 20.52

20.77

20.35

20.66 19.77

19.58

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

Aug.'06

July '06

June '06

May '06

18.21

Apr '06

22.50 22.00 21.50 21.00 20.50 20.00 19.50 19.00 18.50 18.00

Steam Ratio – Apr ’05 to Mar.’07

Apr'05- Mar'06

STEAM (Kg./ Kg. Yarn)

Tyre Cord Plant

CENTURY RAYON CSY Plant 1.115 1.105

1.095

1.100

1.080 1.075

1.075 1.065

1.067

1.065 1.060

1.059

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

Aug.'06

July '06

June '06

May '06

1.044

Apr '06

1.120 1.110 1.100 1.090 1.080 1.070 1.060 1.050 1.040

Apr'05- Mar'06

PULP (Kg./ Kg. Yarn)

Pulp Ratio – Apr ’05 to Mar.’07

CENTURY RAYON 5.86 5.74

5.43

5.48 5.11

5.27

4.74 4.46

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

4.16

Aug.'06

3.83

July '06

3.94

June '06

4.05

May '06

4.53

Apr '06

6.200 5.900 5.600 5.300 5.000 4.700 4.400 4.100 3.800 3.500

Power Ratio – Apr ’05 to Mar.’07

Apr'05- Mar'06

POWER (KWH /Kg. Yarn)

CSY Plant

CENTURY RAYON Caustic Ratio – Apr ’05 to Mar.’07

0.655

0.650

0.645 0.630 0.630

0.630 0.630 0.630 0.630

0.625 0.625

0.625

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

July '06

June '06

May '06

Apr '06

Oct.'06

0.620

0.615

Sept. '06

0.625

0.630

Aug.'06

0.635

0.640

Apr'05- Mar'06

CAUSTIC (Kg./ Kg. Yarn)

CSY Plant

Year

60

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

48

Sept. '06

Aug.'06

39

July '06

42

June '06

May '06

49

Apr '06

62 60 58 56 54 52 50 48 46 44 42 40 38 Apr'05- Mar'06

WATER (Gallons/ Kg. Yarn)

CENTURY RAYON CSY Plant

Water Consumption – Apr ’05 to Mar.’07 61

56

54 56

50

47

42

39

CENTURY RAYON 41.62

43.69

43.29

41.19 39.56 37.01

36.02 35.29

34.81 32.09

30.87

Year

Mar.'07

Feb.'07

Jan.'07

Dec. '06

Nov. '06

Oct.'06

Sept. '06

July '06

June '06

May '06

Aug.'06

28.26

28.63

Apr '06

44.00 42.00 40.00 38.00 36.00 34.00 32.00 30.00 28.00

Steam Ratio – Apr ’05 to Mar.’07

Apr'05- Mar'06

STEAM (Kg./ Kg. Yarn)

CSY Plant

Year

2 1 Mar.'07

1

Feb. '07

5

Jan. '07

2

Dec. '06

2

Nov. '06

4

Oct. '06

4

Sept. '06

Aug. '06

2

July '06

3

June '06

2

May '06

4

Apr. '06

3

Mar.'06

4

Feb. '06

5

Jan '06

3

Avg. (2005)

No. of Accidents

CENTURY RAYON

ACCIDENTS IN TYRE CORD PLANT ( Including Contract Workers )

6

5

4

3 1

1

0

CENTURY RAYON Master List of Objectives & Targets Tyrecord Viscose (P)

To reduce CSY pulp ratio From 1.080 to 1.070 To reduce the total Energy consumption From 12000 kwh to 11880 kwh

Spinbath (P)

Spinning (P)

To reduce Steam consumption of Tyre 20 Tons/Ton of yarn to 19.5 Tons/Ton of yarn

Yarn

To reduce Filtered water gallons/day to 300000 gallons/day

From

consumption

From 350000

To reduce water consumption By 5% To minimise viscose waste due to idle positions By 5%

Textile (P)

To reduce the Mandays loss due to accidents to nil

Maintenance

To reduce the total Energy consumption From 1.5 KW to 1.1 KW To reduce the water pollution